Process for the production of a textile product

ABSTRACT

A process for the production of a textile product includes placing a flat motif template on a textile substrate, sewing the motif template onto the textile substrate in such a way that a perforation defining a desired motif in the motif template is produced, removing the part of the motif template, that is outside the motif defined by the perforation, and permanently fixing the remaining part, having the motif, of the motif template to the textile substrate.

This application is a Continuation application of U.S. Ser. No.13/576,419, filed on Aug. 3, 2012, which is a U.S. national stageapplication of PCT international application PCT/EP2011/050539 filed on17 Jan. 2011, and claims priority of both U.S. provisional patentapplication 61/300,494 filed on 2 Feb. 2010 and German patent document10 2010 001 511.3 filed on 2 Feb. 2010, the entireties of which areincorporated herein by reference.

BACKGROUND OF THE INVENTION

Field of the Invention

The invention concerns a process for the production of a textileproduct, in particular a textile product provided with a motif havingreflecting properties.

State of the Art

DE 1 446 828 A1 discloses a reflecting transfer film and a process forthe production of reflex-reflecting articles, for example for markingarticles of clothing. The transfer film has a transfer layer comprisingan adhesive layer and a rubber-like binding agent layer disposed thereonwith incorporated microballs projecting partially therefrom, and aprotective layer which is disposed on the adhesive side of the transferlayer and which can be pulled off. On its front side the transfer layerhas a dimensionally stable carrier substrate which can be pulled off dryafter the gluing-on operation. To transfer it onto an article ofclothing a hot iron is firmly pressed onto the carrier substrate of theassembly and then the carrier substrate is pulled off thereflex-reflecting transfer film. To apply markings of different kinds ofshapes the motifs in question firstly have to be cut out and thenapplied to the subjacent article of clothing or fabric.

It is further known in the state of the art for reflecting motifs whichare transferred onto a textile product such as for example an article ofclothing, in particular individual or free-standing letters, to beprovided with a peripherally extending seam after the transferoperation, which admittedly in consideration of the resultingcombination of reflecting and non-reflecting reproduction of the motif,leads to attractive effects, but that makes the process overall inconsideration of the multiplicity of process steps required and inparticular the cutting operation which is complex depending on therespective motif involved complicated and also expensive (as aconsequence of the costly laser apparatuses generally used for thecutting operation).

SUMMARY OF THE INVENTION

The object of the present invention is to provide a process for theproduction of a textile product, which in a particularly economicalfashion permits the production of an attractive textile product at acomparatively low level of complication and expenditure.

A process according to the invention for the production of a textileproduct comprises the following steps:

-   -   placing a flat motif template on a textile substrate,    -   sewing the motif template onto the textile substrate in such a        way that a perforation defining a desired motif in the motif        template is produced,    -   removing the part of the motif template, that is outside the        motif defined by the perforation, and    -   permanently fixing the remaining part, having the motif, of the        motif template to the textile substrate.

In that respect here and hereinafter the term “sewing on” in conformitywith the usual terminology is used to denote any operation in which oneor more sewing threads or yarns are passed through a material to besewn, wherein the threads are entwined together or to the material beingsewn. As perforation of the motif template is produced principally bythe step according to the invention of sewing the motif template ontothe textile substrate and as the connection produced in that way betweenthe motif template and the textile substrate becomes a permanent fixing(for example preferably being wash-resistant) only in the fixing step(being the concluding step in the sequence of the foregoing processsteps), the corresponding seam can also be produced with an embroiderymachine. Insofar as and because, after the part of the motif templatedisposed outside the motif defined by the perforation is pulled off,substantially the seam surrounding the desired motif remains andsubsequent permanent fixing is only then effected for example by meansof heat or pressure), the step of sewing or applying the motif templateto the textile substrate can so-to-speak also be referred as “stitchingon”.

The invention is based on the concept, when sewing on a motif templatewhich in particular as explained hereinafter can involve a reflectiontransfer of a suitable configuration, of producing a perforation at thesame time (that is to say so-to-speak in one and the same working step),which perforation permits subsequent removal of the part disposed beyondthe perforation or outside a desired motif.

In that respect either the motif can already be present in the motiftemplate from the outset or it can first be defined by the perforationor the seam producing the perforation. The motif can be for example anyimage motif (including multi-part), alphanumeric characters (that is tosay for example also a sequence of letters or digits), or simply an area(depicted in one or more colors, including white or black andtransparent) which can represent a part of the motif template.

According to the invention therefore with just a few process steps it ispossible to produce an attractive textile product which for exampleshows any lettering on the one hand with a seam forming an outerboundary line and on the other hand in the region within that boundaryline with special properties (that is to say for example reflecting),according to the motif template used.

The process according to the invention considerably simplifies inparticular the conventionally usual processing of a reflection transferin which a reflection transfer is firstly cut in the outer region in acomplicated and expensive operation (generally manually or using a laserdevice). The process makes it possible in particular to produceshort-run series very inexpensively, for example forgery-proof andhigh-value individual manufactures for fan clubs, by a procedure wherebyfor example for a sports organization a film already provided withreflecting logos is produced, to which then individual fan club namescan be sewn on according to the invention. That affords a considerablesaving in time and cost as for example the operation of sewing on orstitching on the logo is no longer required. If a typical number ofstitches of for example between 20,000 and 30,000 stitches per motif isconsidered, the time saving achieved can be of the order of magnitudefor example of about 20 minutes.

In an embodiment the motif template is provided with reflectingproperties. For that purpose preferably a reflection transfer with thefollowing layer structure is used as the motif template: base medium,transfer adhesive, optional intermediate color layer, and reflectioncolor, wherein the reflection color contains a multiplicity ofreflection particles and wherein the reflection particles are raisedabove the surface of the hardened reflection color. The base medium (forexample an adhesive-repellent, silicone-based protective paper) isremoved prior to placement on the textile substrate.

In that respect the invention is based on the realization that areflection transfer of suitable structure, more specifically formed froma transfer adhesive layer and a color layer comprising a reflectioncolor with a multiplicity of reflection particles, permits suchdelimitation of the total thickness of the reflection transfer with atthe same time good reflection particles that the operation according tothe invention of sewing it onto a textile substrate can be implementedwith simultaneous production of a sufficiently clean perforation in thereflection transfer.

In that respect it is to be noted that in the state of the artconventional reflection transfers have a comparatively “closed” orsealed layer which does not at all permit sewing to be effectedtherethrough, or allow a clean perforation effect which that entails. Inparticular, as already explained in the opening part of thisspecification, such reflection transfers generally require a kind of“transfer tape” which is required during the production process as abase layer for application of reflection particles—such applicationoperation being in side-reversed relationship—and which after transferonto the textile substrate closes off the layer structure upwardly, andare consequently not free towards the top side (permitting sewingthrough the entire reflection transfer).

In an embodiment the motif template on the side towards the textilesubstrate has a fixing layer. That fixing layer can be both a fixinglayer for provisional or temporary fixing on the textile substrate(prior to the subsequent operation of sewing it on) and also a fixinglayer which permits concluding permanent fixing, for example under theeffect of heat and/or pressure).

In an embodiment the step of placing the motif template on the textilesubstrate includes at least temporary fixing of the motif template onthe textile substrate, preferably using a spray adhesive.

In an embodiment the motif template has a film made from a thermoplasticmaterial (for example polyurethane or polyamide). The motif template canfurther have a suitable screen printing adhesive (for example asdescribed in EP 1 137 546 B1).

In an embodiment a motif template with a total thickness in the range ofbetween 15 μm and 100 μm, in particular in the range of between 25 μmand 85 μm, is used.

In an embodiment the desired motif is represented in the correct siderelationship in plan view by the reflection color in the reflectiontransfer. Such a representation in correct side relationship isimplemented precisely by the above-described reflection transfer ofsuitable structure, it avoids the use, which is usual in the state ofthe art, of a “transfer tape”, as is required during the productionprocedure as a base layer for applying reflection particles inside-reversed relationship, and it thus makes it possible to sew throughthe entire reflection transfer in accordance with the invention.

The invention further concerns a textile product produced by a processaccording to the invention.

Further configurations of the invention are to be found in thedescription and the appendant claims.

The invention is described in greater detail hereinafter by means ofembodiments by way of example illustrated in the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a flow chart to describe a process according to theinvention in a preferred embodiment,

FIGS. 2a-f show diagrammatic views to illustrate the process accordingto the invention, and

FIG. 3 is a diagrammatic view of a reflection transfer used in theprocess of FIGS. 1 and 2.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

A preferred embodiment of the process according to the invention willnow be described with reference to the flow chart shown in FIG. 1 andthe diagrammatic views serving for illustrative purposes in FIGS. 2athrough 2 f.

Referring to FIG. 2a , firstly a motif template 10 in the form of areflection transfer, the structure of which will be described in greaterdetail with reference to FIG. 3, is provided with an adhesive layer 20in the form of a spray adhesive for provisional fixing, and is thenplaced on a textile substrate 30 (for example a T-shirt) (step S10), inwhich case also a stitching non-woven fabric or embroidery backing 40 isplaced under the textile substrate 30.

The motif template 10 or the reflection transfer has a motif (whereinthat motif can already be present in the motif template from the outsetor can first be defined by the perforation described hereinafter or theseam producing the perforation). That motif can be for example any imagemotif, alphanumeric characters (that is to say for example a successionof letters or digits) or also simply a surface (which is of one or morecolors, including white or black and transparent). In the case of asequence of letters or digits the seam can also extend around eachindividual one of the characters (that is to say for example eachindividual, free-standing letter). In that way, it is possible toachieve in the finished textile product an improved feel in thematerial, in comparison with sewing on a larger motif over a full area.

In step S20 the motif template 10 or the reflection transfer 10 (afterpulling the base medium off the layer structure shown in FIG. 3) is sewnonto the assembly consisting of the textile substrate 30, the adhesivelayer 20 and the stitching non-woven material or backing 40, in such away that at least one perforation is produced in the motif template 10,to define the motif which is desired on the textile product to beproduced. That operation of sewing on the motif template 10 firstlyincludes producing a first seam 50 in the form of a tacking stitch, asshown in FIG. 2c , preferably with a stitch length in the range ofbetween 2 mm and 2.5 mm, followed by the production of a second seam 60in the form of a satin stitch, preferably of a stitch length in therange of between 2 mm and 3 mm in length, as shown in FIG. 2d . It willbe appreciated however that the invention is not limited to thosestitching or sewing stitches which are stated only by way of example,but can also be implemented with any other kinds of stitch with whichthe motif template 10 or film is perforated.

Then as shown in FIG. 2e in step S30 that portion 10 b of the motiftemplate 10, that does not belong to the motif desired on the textileproduct to be produced or that is disposed beyond the perforation, isremoved for example manually, in which respect use is made of the factthat the motif template 10 is well perforated by the seams 50, 60previously produced in step S20.

Thereupon in step S40 as shown in FIG. 2f the textile product togetherwith the remaining part of the motif template 10 or the reflectiontransfer is laid under a transfer press 70 for permanent fixing and ispermanently fixed by means of heat and/or pressure, being pressed forexample for a period of between 5 and 20 seconds at a temperature ofbetween 120 and 180° C.

The reflection transfer used as the motif template 10 is preferably ofthe structure diagrammatically shown in FIG. 3, that is to say itincludes in that sequence a base medium 11, a transfer adhesive 12, anoptional intermediate color layer 15 and reflection color 13, whereinthat reflection color 13 contains a multiplicity of reflection particles14 (for example of a maximum size of 45 .mu.m) and wherein thereflection particles 14 are raised above the surface of the hardenedreflection color 13. Suitable processes for the production of such areflection transfer are described in EP 1 137 546 B1. The base medium 11can be an adhesive-repellent, for example silicone-based, protectionpaper which is pulled off prior to placement of the reflection transferon the textile substrate. The transfer adhesive 12 used within thereflection transfer 10 can be applied to the base medium 11 by means ofany suitable process, for example an extrusion process, a screenprinting process (as described in EP 1 137 546 B1), a suitable coatingprocess or in some other fashion.

A suitable transfer adhesive 12 is for example a thermoplasticco-polyester hot melt adhesive film. The film or the transfer adhesive12 should be of a strength sufficient for the sewing-on operation and inparticular on the one hand should not be too soft in order to prevent itfrom sticking to the needle which is used during the sewing-on operationand which heats up the adhesive in the upward and downward movement.Optionally for that purpose the transfer adhesive 12 can be providedwith reinforcing particles. On the other hand the film or the transferadhesive 12 should not be too hard in order still to permit the needleto pass therethrough without any problem and to allow it to besubsequently torn off along the perforation line produced.

In a further embodiment a laser unit can also be additionally integratedin the apparatus used for the sewing-on operation according to theinvention in order to provide for laser processing in accuraterelationship during or after the above-described steps on the respectivearrangement which is sewn on and secured in place. Although the motiftemplate or film is already sufficiently perforated by the describedprocess steps to permit removal (for example by being torn off) ofunwanted film portions, it is additionally possible to use the laserunit to pass over the reflection transfer or the film in order to hatchfor example the surface thereof, to “destroy” the reflection at thesurface in region-wise fashion in specifically targeted manner and toachieve attractive effects (“reflection/non-reflection”). In thatrespect use is made of the fact that, in the case of the above-describedreflection transfer used in accordance with the invention, the surfacewith the reflection particles is open upwardly and is not covered with atransfer tape. In addition, non-reflecting elements 16 such as forexample flock strips, non-reflecting colors and so forth can also beapplied by printing to the reflecting regions.

Even if the invention has been described by reference to specificembodiments numerous variations and alternative embodiments will beapparent to the man skilled in the art, for example by combinationand/or exchange of features of individual embodiments. Accordingly itwill be appreciated by the man skilled in the art that such variationsand alternative embodiments are also embraced by the present inventionand the scope of the invention is limited only in the sense of theaccompanying claims and equivalents thereof.

The invention claimed is:
 1. A process for the production of a textileproduct, comprising: a) placing a flat motif template on a textilesubstrate, b) sewing the motif template onto the textile substrate insuch a way that a perforation defining a desired motif in the motiftemplate is produced, c) removing the part of the motif template, thatis outside the motif defined by the perforation, and d) permanentlyfixing the remaining part, having the motif, of the motif template tothe textile substrate, wherein step a) includes provisional fixing ofthe motif template on the textile substrate using a spray adhesive.
 2. Aprocess as set forth in claim 1 wherein the motif template has a fixinglayer on the side towards the textile substrate.
 3. A process as setforth in claim 1, wherein the motif template comprises a film made froma thermoplastic material.
 4. A process as set forth in claim 1, whereina motif template has a total thickness in the range of between 15 μm and100 μm.
 5. A process as set forth in claim 1, wherein the motif templatehas reflecting properties.
 6. A process as set forth in claim 5 whereina reflection transfer with the following layer structure comprises themotif template: base medium, transfer adhesive, optional intermediatecolor layer, and reflection color, wherein the reflection colorcomprises a multiplicity of reflection particles and wherein thereflection particles are raised above the surface of the hardenedreflection color.
 7. A process as set forth in claim 6 wherein in thereflection transfer the desired motif is represented in correct-siderelationship in plan view by the reflection color.
 8. A process as setforth in claim 5, further comprising the step of applying or printingnon-reflecting elements to reflecting regions having said reflectingproperties.
 9. A textile product produced by a process as set forth inclaim
 1. 10. A textile product as set forth in claim 9, wherein thetextile product comprises a motif with a seam forming an outer boundaryline and, within that boundary line, with reflecting properties.
 11. Aprocess as set forth in claim 1, wherein by sewing the motif templateonto the textile substrate in such a way that a perforation defining adesired motif in the motif template is produced, the motif template isalready sufficiently perforated to permit a manual removal of the partsnot belonging to the desired motif.
 12. A process as set forth claim 1,wherein step d) of permanently fixing the remaining part is performedusing heat or pressure.
 13. A process as set forth in claim 1, whereinstep b) of sewing is performed as stitching the motif template onto thetextile substrate.
 14. A process as set forth in claim 1, wherein themotif is first defined by the perforation.
 15. A process as set forth inclaim 1, wherein motif is a multi-part motif.
 16. A process as set forthin claim 1, wherein the motif template has a total thickness in therange of between 25 μm and 85 μm.
 17. A textile product produced by theprocess as set forth in claim
 1. 18. A process for the production of atextile product, comprising: a) placing a flat motif template on atextile substrate, the motif template having a fixing layer on a sidetowards the textile substrate; b) sewing the motif template onto thetextile substrate in such a way that a perforation defining a desiredmotif in the motif template is produced, the motif template beingalready sufficiently perforated to permit a manual removal of the partsnot belonging to the desired motif; c) removing the part of the motiftemplate that is outside the motif defined by the perforation, and d)permanently fixing the remaining part, having the motif, of the motiftemplate to the textile substrate, wherein step a) includes provisionalfixing of the motif template on the textile substrate using a sprayadhesive.
 19. A process for the production of a textile product,comprising: a) placing a flat motif template on a textile substrate, b)sewing the motif template onto the textile substrate in such a way thata perforation defining a desired motif in the motif template isproduced, c) removing the part of the motif template, that is outsidethe motif defined by the perforation, and d) permanently fixing theremaining part, having the motif, of the motif template to the textilesubstrate, wherein the motif template has reflecting properties, whereina reflection transfer with the following layer structure comprises themotif template: base medium, transfer adhesive, optional intermediatecolor layer, and reflection color, wherein the reflection colorcomprises a multiplicity of reflection particles and wherein thereflection particles are raised above the surface of the hardenedreflection color.
 20. A process for the production of a textile product,comprising: a) placing a flat motif template having reflectingproperties on a textile substrate, b) sewing the motif template onto thetextile substrate in such a way that a perforation defining a desiredmotif in the motif template is produced, c) removing the part of themotif template, that is outside the motif defined by the perforation,and d) permanently fixing the remaining part, having the motif, of themotif template to the textile substrate, and e) applying or printingnon-reflecting elements to reflecting regions having said reflectingproperties.